OWNER’S OPERATING MANUAL

MMA INVERTER WELDERMODEL MMA-140

KEEP THIS MANUAL FOR FUTURE REFERENCE

Your new inverter generator has been engineered and manufactured to Ryobi’shigh standard of dependability, ease of operation and operator safety. Properlycared for, it will give you years of rugged, trouble free performance. If you useyour inverter generator properly and only for what it is intended, you will enjoyyears of safe, reliable service.

SPECIFICATIONS

Rated input power supply......................................................AC 230V±5% 50/60HzRated input capacity......................................................................................5.3KVACurrent adjustment range........................................................................... 20-140ARated duty cycle................................................................................................ 80%Rated voltage..........................................................................................20.8-25.6No load voltage.................................................................................................. 63V

V

Overall efficiency................................................................................................80%Housing protection grade................................................................................ IP21SPower factor..............................................................................................0.73 cosφInsulation grade...................................................................................................... FElectrode diameter...................................................................................1.6-3.2mmNoise......................................................................................................... <70dB(A)Dimensions............................................................................... 287 x 120 x 247mmNet weight........................................................................................................ 3.8kg

THANK YOU FOR BUYING A RYOBI

MMA INVERTER WELDER

CAUTION: Carefully read through this entire owner’smanual, paying close attention to the generalsafety rules and rules for safe operation,before using.

1

2

IMPORTANT SAFETY INSTRUCTIONSThe purpose of safety rules is to attract yourattention to possible dangers. The safety symbolsand the explanations with them, require yourcareful attention and understanding. The safetywarnings do not by themselves eliminate anydanger. The instruction or warnings they give arenot substitutes for proper accident preventionmeasures.

SAFETY ALERT SYMBOL. Indicatesdanger, caution or warning. May be usedin conjunction with other symbols orpictures.

Failure to obey a safety warning can result inserious injury to yourself or to others. Always followthe safety precautions to reduce the risk of fire,electric shock and personal injury.

Do not attempt to operate this tool until you haveread thoroughly and completely understood thesafety rules, etc. contained in this manual. Failureto comply can result in accidents involving fire,electric shock or serious personal injury. Save thisOwners Operating Manual and review it frequentlyfor continual safe operation and for instructingothers who may use this tool.

EMF INFORMATIONConsiderations About Welding And The Effects OfLow Frequency Electric And Magnetic Fields.Welding current, as it flows through welding cables,will cause electro- magnetic fields. There has beenand still is some concern about such fields.However, after examining more than 500 studiesspanning 17 years of research, a special blueribbon committee of the National Research Councilconcluded that: “The body of evidence, in thecommittee’s judgment, has not demonstrated thatexposure to power- frequency electric andmagnetic fields is a human-health hazard.”However, studies are still going forth and evidencecontinues to be examined. Until the finalconclusions of the research are reached, you maywish to minimize your exposure to electromagneticfields when welding or cutting.

To reduce magnetic fields in the workplace, use thefollowing procedures:

1. Keep cables close together by twisting ortaping them.

2. Arrange cables to one side and away fromthe operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as faraway from operator as practical.

5. Connect work clamp to work piece as closeto the weld as possible.

ABOUT PACEMAKERSPacemaker wearers consult your doctor first. Ifcleared by your doctor, then following the aboveprocedures is recommended.

WELDING HAZARDSThe symbols shown below are used throughout thismanual to call attention to and identify possiblehazards. When you see the symbol, watch out, andfollow the related instructions to avoid the hazard.

Only qualified persons should service, test,maintain, and repair this unit.

During servicing, keep everybody, especiallychildren, away.

ARC RAYS can burn eyes and skin; NOISE candamage hearing. Arc rays from the weldingprocess produce intense heat and strongultraviolet rays that can burn eyes and skin.Noise from some processes can damagehearing.

1. Wear a welding helmet fitted with a propershade of filter (ANSI Z49.1) to protect yourface and eyes when welding or watching.

2. Wear approved safety glasses. Side shieldsrecommended. Never wear contact lenseswhile welding.

3. Use protective screens or barriers to protectothers from flash and glare; warn others notto watch the arc.

4. Wear protective clothing made from durable,flame-resistant material (wool and leather)and foot protection.

5. Use approved ear plugs or ear muffs if noiselevel is high.

ARC RAYSCan Burn

3

IMPORTANT SAFETY INSTRUCTIONS

4

IMPORTANT SAFETY INSTRUCTIONS

Touching live electrical parts can cause fatalshocks or severe burns. The electrode andwork circuit is electrically live whenever theoutput is on. The input power circuit andmachine internal circuits are also live whenpower is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive rollhousing, and all metal parts touching thewelding wire are electrically live. Incorrectlyinstalled or improperly grounded equipment isa hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and bodyprotection.

3. Insulate yourself from work and ground usingdry insulating mats or covers.

4. Disconnect input power or stop engine beforeinstalling or servicing this equipment. Lock inputpower disconnect switch open, or remove linefuses so power cannot be turned onaccidentally.

5. Properly install and ground this equipmentaccording to its Owner’s Manual and national,state, and local codes.

6. Turn off all equipment when not in use.Disconnect power to equipment if it will be leftunattended or out of service.

7. Use fully insulated electrode holders. Never dipholder in water to cool it or lay it down on theground or the work surface. Do not touchholders connected to two welding machines atthe same time or touch other people with theholder or electrode.

8. Do not use worn, damaged, undersized, orpoorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical(earth) ground.

11. Do not touch electrode while in contact withthe work (ground) circuit.

12.Use only well-maintained equipment. Repairor replace damaged parts at once.

13. In confined spaces or damp locations, do notuse a welder with AC output unless it isequipped with a voltage reducer. Useequipment with DC output.

14.Wear a safety harness to prevent falling ifworking above floor level.

15. Keep all panels and covers securely in place.

FUMES AND GASES can be hazardous to yourhealth. Welding produces fumes and gases.Breathing these fumes and gases can be haz-ardous to your health.

1. Keep your head out of the fumes. Do notbreath the fumes.

2. If inside, ventilate the area and/or useexhaust at the arc to remove welding fumesand gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets(MSDSs) and the manufacturer’s instructionfor metals, consumables, coatings, andcleaners.

5. Work in a confined space only if it is wellventilated, or while wearing an air-suppliedrespirator.

Shielding gases used for welding can displaceair causing injury or death. Be sure thebreathing air is safe.

6. Do not weld in locations near degreasing,cleaning, or spraying operations. The heatand rays of the arc can react with vapors toform highly toxic and irritating gases.

7. Do not weld on coated metals, such asgalvanized, lead, or cadmium plated steel,unless the coating is removed from the weldarea, the area is well ventilated, and ifnecessary, while wearing an airsuppliedrespirator. The coatings and any metalscontaining these elements can give off toxicfumes if welded.

ELECTRIC SHOCKCan Kill

FUMES & GASESCan Be Dangerous

FLYING SPARKS AND HOT METAL can causeinjury.

Chipping and grinding cause flying metal.

As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles.Side shields recommended.

2. Wear proper body protection to protect skin.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode.Since gas cylinders are normally part of thewelding process, be sure to treat themcarefully.

1. Protect compressed gas cylinders fromexcessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an uprightposition by chaining them to a stationarysupport or equipment cylinder rack toprevent falling or tipping.

3. Keep cylinders away from any welding or otherelectrical circuits.

4. Never allow a welding electrode to touch anycylinder.

5. Use only correct shielding gas cylinders,regulators, hoses, and fittings designed for thespecific application; maintain them andassociated parts in good condition.

6. Turn face away from valve outlet when openingcylinder valve.

7. Keep protective cap in place over valve exceptwhen cylinder is in use or connected for use.

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc.The flying sparks and hot metal, weld spatter,hot workpiece, and hot equipment can causefires and burns. Accidental contact of electrodeor welding wire to metal objects can causesparks, overheating, or fire.

1. Protect yourself and others from flying sparksand hot metal.

2. Do not weld where flying sparks can strikeflammable material.

3. Remove all flammables within 35 ft (10.7 m) ofthe welding arc. If this is not possible, tightlycover them with approved covers.

4. Be alert that welding sparks and hot materialsfrom welding can easily go through smallcracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguishernearby.

6. Be aware that welding on a ceiling, floor,bulkhead, or partition can cause fire on thehidden side.

7. Do not weld on closed containers such astanks or drums.

8. Connect work cable to the work as close tothe welding area as practical to preventwelding current from traveling long, possiblyunknown paths and causing electric shock andfire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut offwelding wire at contact tip when not in use.

11. When not welding, make certain no part of theelectrode circuit is touching the work orground. Accidental contact can causeoverheating and create a fire hazard.

5

IMPORTANT SAFETY INSTRUCTIONS

FLYING SPARKSCan Cause Injury

CYLINDERS CanExplode If Damaged

WELDING CanCause Fire or Injury

6

IMPORTANT SAFETY INSTRUCTIONS

Moving parts, such as fans, rotors, and beltscan cut fingers and hands and catch looseclothing.

1. Keep all doors, panels, covers, and guardsclosed and securely in place.

2. Stop engine before installing or connectingunit.

3. Have only qualified people remove guards orcovers for maintenance and troubleshooting asnecessary.

4. To prevent accidental starting during servicing,disconnect negative (-) battery cable frombattery.

5. Keep hands, hair, loose clothing, and toolsaway from moving parts.

6. Reinstall panels or guards and close doorswhen servicing is finished and before startingengine.

SPARKS can cause BATTERY GASES TO EX-PLODE; BATTERY ACID can burn eyes andskin. Batteries contain acid and generate explo-sive gases.

1. Always wear a face shield when working ona battery.

2. Stop engine before disconnecting orconnecting battery cables.

3. Do not allow tools to cause sparks whenworking on a battery.

4. Do not use welder to charge batteries or jumpstart vehicles.

5. Observe correct polarity (+ and –) on

STEAM AND PRESSURIZED HOT COOLANTcan burn face, eyes, and skin.

The coolant in the radiator can be very hot andunder pressure.

1. Do not remove radiator cap when engine ishot. Allow engine to cool.

2. Wear gloves and put a rag over cap area whenremoving cap.

3. Allow pressure to escape before completelyremoving cap.

1. High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

2. Have only qualified persons familiar withelectronic equipment install, test, and serviceH.F. producing units.

3. The user is responsible for having a qualifiedelectrician promptly correct any interferenceproblem resulting from the installation.

4. If notified by the FCC about interference, stopusing the equipment at once.

5. Have the installation regularly checked andmaintained.

6. Keep high-frequency source doors and panelstightly shut, keep spark gaps at correct setting,and use grounding and shielding to minimizethe possibility of interference.

MOVING PARTSCan Cause Injury

SPARKS Can CauseBATTERY GASESTO EXPLODE

SPARKS Can CauseBATTERY GASESTO EXPLODE

H.F. RADIATION CanCause Interference

1. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields(EMF). Welding current creates EMF fieldsaround welding cables and welding machines.

2. EMF fields may interfere with somepacemakers, and welders having a pacemakershould consult their physician before welding.

3. Exposure to EMF fields in welding may haveother health effects which are now not known.

4. All welders should use the followingprocedures in order to minimize exposure toEMF fields from the welding circuit:

5. Route the electrode and work cables together -Secure them with tape when possible.

6. Never coil the electrode lead around yourbody.

7. Do not place your body between the electrodeand work cables. If the electrode cable is onyour right side, the work cable should also beon your right side.

8. Connect the work cable to the workpiece asclose as possible to the area being welded.

9. Do not work next to welding power source.

1. Lift unit with handle on top of case.

2. Use handcart or similar device of adequatecapacity.

3. If using a fork lift vehicle, place and secureunit on a proper skid before transporting.

1. Turn off input power using the disconnectswitch at the fuse box before working on theequipment.

2. Install equipment in accordance with thecountries National Electrical Code, all localcodes and the manufacturer’srecommendations.

3. Ground the equipment in accordance with thecountries National Electrical Code and themanufacturer’s recommendations.

1. Do not touch hot parts bare handed.

2. Allow cooling period before working onwelding gun or torch.

1. Do not place unit on, over, or nearcombustible surfaces.

2. Do not service unit near flammables.

1. Put on grounded wrist strap BEFORE handlingboards or parts.

2. Use proper static-proof bags and boxes tostore, move, or ship PC boards.

7

IMPORTANT SAFETY INSTRUCTIONS

ELECTRIC ANDMAGNETIC FIELDSMay Be Dangerous

FALLING UNIT CanCause Injury

FOR ELECTRICALLYPowered Equipment

HOT PARTS CanCause Severe Burns

FIRE or EXPLOSIONHazard

STATIC Can DamagePC Boards

8

IMPORTANT SAFETY INSTRUCTIONS

1. Allow cooling period; follow rated duty cycle.

2. Reduce current or reduce duty cycle beforestarting to weld again.

3. Do not block or filter airflow to unit.

1. Consult the Owner’s Manual for weldingsafety precautions. Do not install, operate orrepair this equipment without reading thismanual and the safety precautions throughout.

2. Use only genuine replacement parts

OVERUSE CausesOVERHEATING

READ THEINSTRUCTIONS

ADDITIONAL SAFETY INSTRUCTIONS1. ALWAYS ensure that there is full free air

circulating around the outer casing of themachine, and that the louvres areunobstructed.

2. ALWAYS use a proper welding face shield orhelmet, with suitable filter lenses. Propergloves and working clothes should be worn atall times.

3. ALWAYS check that the pressure regulator andgauges are working correctly. DO NOTlubricate the regulator.

4. ALWAYS use the correct regulator. Eachregulator is designed to be used with a specificgas.

5. ALWAYS inspect the hose before use toensure it is in good condition.

6. ALWAYS keep the free length of gas hoseoutside the work area.

7. ALWAYS remove all flammable materials fromthe welding area.

8. NEVER remove any of the panels unless themachine is disconnected from the supply, ANDnever use the machine with any of the panelsremoved.

9. NEVER attempt any electrical or mechanicalrepair unless your are a qualified technician.If you have a problem with the machine contactyour local RYOBI dealer.

10. NEVER use or store in a wet/dampenvironment. DO NOT EXPOSE TO RAIN.

11. NEVER use gas from a cylinder, the contentof which is unknown. It is important to ensurethe appropriate gas is being used.

12. NEVER use a damaged cylinder.

13. NEVER lift the cylinder by the valve.

14. NEVER expose the cylinder to a heat sourceor sparks.

15. NEVER continue to weld, if, at any time, youfeel even the smallest electric shock. Stopwelding IMMEDIATELY, and DO NOT attemptto use the machine until the fault is diagnosedand corrected.

16. NEVER use the welder with input connectionsgreater than 10M in length.

17. NEVER point the torch at any person oranimal.

18. NEVER touch the torch nozzle until the welderis switched OFF and the nozzle has beenallowed to cool off.

19. NEVER connect, disconnect, or attempt toservice the torch, until the machine is switchedOFF and disconnected from the mains supply.

20. NEVER allow the cables to become wrappedaround the operator or any person in thevicinity.

21. Safety devices such as interlocks and circuitbreakers should not be disconnected orshunted out.

22. Before installation, inspection, or service ofequipment, shut OFF all power and removeline fuses to prevent accidental turning ONof power.

23. Do not open power circuit or change polaritywhile welding.

9

ADDITIONAL SAFETY INSTRUCTIONS24. If, in an emergency, it must be disconnected,

guard against shock burns, or flash from switcharcing. Always shut OFF and disconnect allpower to equipment. Power disconnect switchmust be available near the welding powersource.

25. Fully insulated electrode holders should beused. Do NOT use holders with protrudingscrews or with any form of damage.

26. Fully insulated lock-type connectors should beused to join welding cable.

27. Frequently inspect cables for wear, cracks anddamage. IMMEDIATELY REPLACE those withexcessively worn or damaged insulation toavoid possibly lethal shock from bared cable.Cables with damaged areas may be taped togive resistance equivalent to original cable.Keep cable dry, free of oil and grease, andprotected from hot metal and sparks.

INSTALLATIONENVIRONMENTThese units are designed for use in environmentswith increased hazard of electric shock.

A. Examples of environments with increasedhazard of electric shock are:

1. In locations in which freedom of movement isrestricted, so that the operator is forced toperform the work in a cramped (kneeling,sitting or lying) position with physical contactwith conductive parts.

2. In locations which are fully or partially limitedby conductive elements, and in which there isa high risk of unavoidable or accidental contactby the operator.

3. In wet or damp hot locations where humidityor perspiration considerable reduces the skinresistance of the human body and theinsulation properties of accessories.

B. Environments with increased hazard of electricshock do not include places where electricallyconductive parts in the near vicinity of theoperator, which can cause increased hazard,have been insulated.

LOCATIONThis machine can operate in harsh environments.However, it is important that simple preventativemeasures are followed to assure long life and reli-able operation:

• This machine must be located where there isfree circulation of clean air without restrictionsfor air movement to and from the air vents. Donot cover the machine with paper, cloth or ragswhen switched on.

• Dirt and dust that can be drawn into themachine should be kept to a minimum.

• This machine has a protection rating of IP21S.Keep it dry and do not place it on wet groundor in puddles. Do not use in wet or damplocations. Store indoors.

• Locate the machine away from radio controlledmachinery. Normal operation may adverselyaffect the operation of nearby radio controlledmachinery, which may result in injury orequipment damage.

Read the section on electromagnetic compatibilityin this manual.

• Do not operate in areas with an ambienttemperature greater than 40°C.

TILTINGPlace the machine directly on a secure, levelsurface.

Do not place or operate this machine on a surfacewith an incline greater than 15° from horizontal.The machine may topple over if this procedure isnot followed.

VENTILATIONThis cutting machine can create powerful cuttingcurrent and has strict cooling requirements thatcannot be met with natural ventilation. Thereforethe built-in fan is very important in enabling themachine to work stable with effective cooling. Theoperator should make sure that the louvers beuncovered and unblocked. The minimum distancebetween the machine and nearby objects shouldbe 25cm.

10

INSTALLATIONCONNECTION OF INPUT CABLEIn order to ensure personal safety and avoidelectric shock, please ground the machine reliablyby connecting the ground wire of the machine tothe grounding device in the switching box.

The primary cable should be tightly connected tothe correct socket to avoid oxidization.

Check whether the voltage value varies inacceptable range with a multi-meter.

The Mains supply voltage should be within ± 5% ofthe rated Mains supply voltage. Too low avoltage may cause poor welding performance. Toohigh a supply voltage will cause components tooverheat and possibly fail.

The Welding Power Source must be:

• Correctly installed, if necessary, by a qualifiedelectrician.

• Correctly earthed (electrically) in accordancewith local regulations.

DUTY CYCLEThe rated duty cycle of a Welding Power Source, isa statement of the time it may be operated at itsrated welding current output without exceeding thetemperature limits of the insulation of thecomponent parts.

This product has a rated duty cycle of 80%. Thepercentage represents the welding time in a 10minute period for example 80% means that thewelding time is 8 minutes with a rest time of 2

minutes in a ten minute period although the actualduty cycle will depend on the amperage used. If theWelding Power Supply is used for longer than theduty cycle or if you are welding using large weldingrods you may experience a temporary current shutoff. This is to protect the transformer inside theWelding Power Supply from overheating.

Welding longer than rated duty cycle candamage gun and void the warranty.

ELECTROMAGNETIC COMPATIBILITYWARNING. Extra precautions forElectromagnetic Compatibility may berequired when this Welding Power

Source is used in a domestic situation.

A. Installation and Use - Users ResponsibilityThe user is responsible for installing and using thewelding equipment according to the manufacturer’sinstructions. If electromagnetic disturbances aredetected then it shall be the responsibility of theuser of the welding equipment to resolve thesituation with the technical assistance of themanufacturer. In some cases this remedial actionmay be as simple as earthing the welding circuit,see Note below. In other cases it could involveconstructing an electromagnetic screen enclosingthe Welding Power Source and the work, completewith associated input filters. In all cases,electromagnetic disturbances shall be reduced tothe point where they are no longer troublesome.

Note: The welding circuit may or may nor beearthed for safety reasons. Changing the earthingarrangements should only be authorised by a

person who is competent to assess whether thechanges will increase the risk of injury, e.g. byallowing parallel welding current return paths whichmay damage the earth circuits of other equipment.Further guidance is given in IEC 974-13 ArcWelding Equipment - Installation and use (underpreparation).

B. Assessment of AreaBefore installing welding equipment, the user shallmake an assessment of potential electromagneticproblems in the surrounding area. The followingshall be taken into account:

1. Other supply cables, control cables, signallingand telephone cables; above, below andadjacent to the welding equipment.

2. Radio and television transmitters andreceivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding ofindustrial equipment.

11

ELECTROMAGNETIC COMPATIBILITY5. The health of people around, e.g. the use of

pacemakers and hearing aids.

6. Equipment used for calibration andmeasurement.

7. The time of day that welding or other activitiesare to be carried out.

8. The immunity of other equipment in theenvironment: the user shall ensure that otherequipment being used in the environment iscompatible: this may require additionalprotection measures.

The size of the surrounding area to be consideredwill depend on the structure of the building andother activities that are taking place. The surround-ing area may extend beyond the boundaries of thepremises.

C. Methods of Reducing ElectromagneticEmissions

1. Mains Supply

Welding equipment should be connected tothe mains supply according to themanufacturer’s recommendations. Ifinterference occurs, it may be necessary totake additional precautions such as filteringof the mains supply. Consideration should begiven to shielding the supply cable ofpermanently installed welding equipment inmetallic conduit or equivalent. Shielding shouldbe electrically continuous throughout it’slength. The shielding should be connected tothe Welding Power Source so that goodelectrical contact is maintained between theconduit and the Welding Power Sourceenclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinelymaintained according to the manufacturer’srecommendations. All access and servicedoors and covers should be closed andproperly fastened when the welding equipmentis in operation.The welding equipment should not be modifiedin any way except for those changes andadjustments covered in the manufacturer’sinstructions. In particular, the spark gaps of arcstriking and stabilising devices should beadjusted and maintained according to themanufacturer’s recommendations.

3. Welding Cables

The welding cables should be kept as short aspossible and should be positioned closetogether, running at or close to the floor level.

4. Equipotential Bonding

Bonding of all metallic components in thewelding installation and adjacent to it should beconsidered. However. Metallic componentsbonded to the work piece will increase the riskthat the operator could receive a shock bytouching the metallic components and theelectrode at the same time. The operatorshould be insulated from all such bondedmetallic components.

5. Earthing of the Workpiece

Where the workpiece is not bonded to earth forelectrical safety, nor connected to earthbecause of it’s size and position, e.g. ship’shull or building steelwork, a connectionbonding the workpiece to earth may reduceemissions in some, but not all instances. Careshould be taken to prevent the earthing of theworkpiece increasing the risk of injury to users,or damage to other electrical equipment.Where necessary, the connection of the workpiece to earth should be made by directconnection to the workpiece, but in somecountries where direct connection is notpermitted, the bonding should be achieved bysuitable capacitance, selected according tonational regulations.

6. Screening and Shielding

Selective screening and shielding of othercables and equipment in the surrounding areamay alleviate problems of interference.Screening the entire welding installation maybe considered for special applications.

12

SYMBOL CHART

13

1. Carry handle2. On/Off switch3. Current control knob4. Power indicator5. Thermal cutout indicator6. Earth clamp connection point (- negative)7. Welding mask

8. Electrode holder9. Earth clamp10. Chipping hammer and wire brush11. Cooling fan12. Power lead13. Electrode holder connection point (+ positive)

DESCRIPTION

4

6

5

1

7

12

11

2

13

89

10

3

14

UNPACKING

CAUTION. This packaging containssharp objects. Take care whenunpacking. Remove the machine,

together with the accessories supplied, from thepackaging. Check carefully to ensure that themachine is in good condition and account for all theaccessories listed in this manual. Also make surethat all the accessories are complete.

If any parts are found to be missing, the machineand its accessories should be returned together intheir original packaging to the retailer. Do not throwthe packaging away, keep it safe throughout theguarantee period, then recycle if possible,otherwise dispose of it by the proper means. Donot let children play with empty plastic bags due tothe risk of suffocation.

ASSEMBLY

WARNING. ELECTRIC SHOCK can kill.Keep the electrode holder and cableinsulation in good condition.

Do not touch electrically live parts or electrodewith skin or wet clothing.

Insulate yourself from work and ground.

Turn the input line switch on the welder “OFF”before connecting or disconnecting outputcables or other equipment.

FITTING THE EARTHCLAMP AND ELECTRODEHOLDERInsert the plug on the end of the earth clamp leadinto the negative (-) socket (Fig.1) and twist in aclockwise direction to secure into position.

The plug on the end of the electrode holder can befitted into the positive (+) socket (Fig.1) in the sameway.

A 14020

Fig. 1

15

ASSEMBLYNote: Before carrying out any assembly ordisassembly of the unit please ensure that the unitis not connected to the electrical supply.

ASSEMBLING THE WELDING MASKAttach the handle to the Welding Shield by liningup the two rectangular tabs on the handle with thecorresponding holes in the welding shield and:

A. press the tabs through the holes and thenB. slide the tabs forward from the back, locking the

round tab in place.Insert the clear glass panel followed by the darkglass panel into the recess in the shield, refer toFig.2 & Fig.3.

The dark panel is a certified, specific optical class,and should not be exchanged for any other type.The clear glass panel should be replaced when itbecomes badly pitted.

WARNING! NEVER look at an electricarc without eye protection as this caninjure the eyes permanently. ALWAYS

use a protection mask or welding helmet.

HandleWelding Shield

(viewed from front)

AA

BBRound

Tab

Fig. 2

Welding Shield (viewed from back)

Filter Lens

Fig. 3

OPERATIONDESCRIPTIONYour Welding Power Supply features a singlephase transformer suitable for welding with analternating current using stick electrodes withdiameters from 1.6mm to 5mm. The welding cur-rent is regulated by using the welding current con-trol (regulator).

ELECTRODE SELECTIONThe pages of this manual are restricted to the basicsafe use of an MMA welding power supply and verybasic welding technique. The electrodes used inMMA welding are many and varied. You areadvised to seek advise from your local weldingequipment supplier for the correct selection ofelectrode for the work being performed.

OPERATIONWARNING! If you have no weldingexperience, we recommend you seektraining from an experienced person.

CAUTION: This manual is a basic guideto welding. We recommend youpurchase a good quality publication on

welding or if you have internet access visit one ofthe numerous welding related web sites to be ableto use the welding power supply to its full potential.

THE QUALITY OF ANY WELDED JOINT ISDEPENDANT ON THE PREPARATION OF THEJOINT THE SELECTION OF THE CORRECTELECTRODE AND THE SKILL ANDEXPERIENCE OF THE WELDER.

Ensure the Welding Power Supply is disconnectedfrom the mains supply.

Ensure that the area of the work piece where theearth clamp is to be connected is clean using a fileor a grinder, to ensure a good electrical contact.

Ensure the earth lead is connected to theworkpiece, and the other lead to the electrodeholder.

16

OPERATIONImportant: Ensure also that the earth clamp isattached to clean, solid metal. If necessarythoroughly clean with a wire brush or similar toguarantee a good connection.

The earth clamp must only be connected to thework piece. The area to be welded must be cleanand free from dirt, rust, paint, grease and oil.

Insert an electrode into the electrode holder (Fig.4)ensuring there is a good connection.

Set the amperage (see Table 1) by adjusting theregulator (Fig.5)(A) until the desired setting isreached.

The chart below is an indicator of the electrodediameter and the corresponding welding current.This is intended as a guide only.

WARNING! Always wear a full weldingmask, welding gloves and protectiveclothing. Wear goggles while chippingslag.

Do not switch on the power supply until you areready to start welding. Practice welding on a pieceof scrap material.

Connect to the mains supply and press the On/Offswitch (Fig.6) to the ON position (l) The powerindicator lamp on the front panel (Fig.5)(B) willilluminate. To stop the machine, press the On/Offswitch to the OFF position (0).

Note: If the machine stops at any time and thethermal cut out indicator on the front panelilluminates, the thermal cutout has intervened.

This indicator will turn on when the machine isoverheated and the output has been disabled. This

normally occurs when the duty cycle of themachine has been exceeded. Leave the machineon to allow the internal components to cool. Whenthe indicator turns off, normal operation is againpossible.

Fig. 4

A 20020

Fig. 5

Fig. 6

A

B

Table 1

Electrode Material Weldingsize (mm) thickness current (A)

(mm)

1.6 1 - 1.6 25 - 40

2.0 1.6 - 2.6 40 - 70

2.5 2.6 - 4.0 60 - 100

3.2 3.0 - 5.0 80 - 130

4.0 5.0 - 7.0 130 - 170

5.0 7.0 - 9.0 170 - 200

17

STICK (MMAW) BASIC WELDING TECHNIQUEAWORD TO BEGINNERSFor those who have not yet done any welding, thesimplest way to commence is to run beads on apiece of scrap plate. Use mild steel plate about6.0mm thick and a 3.2mm electrode. Clean anypaint, loose scale or grease off the plate and set itfirmly on the work bench so that welding can becarried out in the downhand position. Make surethat the work clamp is making good electricalcontact with the work, either directly or through thework table. For light gauge material, always clampthe work lead directly to the job, otherwise a poorcircuit will probably result.

THE WELDERPlace yourself in a comfortable position beforebeginning to weld. Get a seat of suitable height anddo as much work as possible sitting down. Don'ttense your body. Relax and you will find that the jobbecomes much easier. Wear a leather apron andgauntlets. This will protect you from being burnt orsparks setting alight to your clothes.

Place the work so that the direction of welding isacross, rather than to or from, your body. Theelectrode holder lead should be clear of anyobstruction so that you can move your arm freelyalong as the electrode burns down. If the lead isslung over your shoulder, it allows greater freedomof movement and takes a lot of weight off yourhand. Be sure the insulation on your cable andelectrode holder is not faulty, otherwise you arerisking an electric shock.

STRIKING THE ARCHolding a face mask in front of your face stroke theelectrode point on the workpiece as if striking amatch.

Maintain a steady gap between the end of theelectrode and the workpiece of approximately 2mm(Fig.7).

Maintain this distance as constantly as possibleduring the weld remember that the angle of theelectrode to the work piece must be 20-30° (Fig.8).

Do not hit the electrode on the workpiece as thismay damage the electrode. Withdraw with a cleanmovement at the end of the welding run.

Note: This is the most difficult aspect for mostbeginners. It is recommended that you practice onsome scrap material in order to get a feel of theoperation.

If the electrode is not withdrawn quickly enoughonce the arc is primed, there is a possibility that theelectrode will weld itself to the workpiece. Shouldthis happen, give it a sharp tug to free it, and tryagain. If this fails to free it, turn off the machineimmediately as it will quickly overheat.

If you withdraw the electrode too far once the arc isprimed, you will lose the arc and have to try again.

Inspect the job carefully. With a correctcombination of electrode size and current settingthe area of weld should be complete fusion of theelectrode and parent metal/s. Any slag which formson the surface should be chipped away with thepick/brush supplied.

If the resultant weld looks messy and irregular, thisis an indication of porosity or slag contamination,and you have almost certainly failed to achieve thecorrect combination. This is a common problem, sodo not worry as practice will quickly cure this.

Fig. 7

Fig. 8

2mm

20º-30º

18

STICK (MMAW) BASIC WELDING TECHNIQUEARC LENGTHThe securing of an arc length necessary to producea neat weld soon becomes almost automatic. Youwill find that a long arc produces more heat. A verylong arc produces a crackling or spluttering noiseand the weld metal comes across in large, irregularblobs. The weld bead is flattened and spatterincreases. A short arc is essential if a high qualityweld is to be obtained although if it is too shortthere is the danger of it being blanketed by slagand the electrode tip being solidified in. If thisshould happen, give the electrode a quick twistback over the weld to detach it. Contact or "touch-weld" electrodes do not stick in this way, and makewelding much easier.

RATE OF TRAVELAfter the arc is struck, your next concern is tomaintain it, and this requires moving the electrodetip towards the molten pool at the same rate as it ismelting away. At the same time, the electrode hasto move along the plate to form a bead. Theelectrode is directed at the weld pool at about 20ºfrom the vertical. The rate of travel has to beadjusted so that a well-formed bead is produced. Ifthe travel is too fast, the bead will be narrow andstrung out and may even be broken up intoindividual globules. If the travel is too slow, theweld metal piles up and the bead will be too large.

MAKING WELDED JOINTSHaving attained some skill in the handling of anelectrode, you will be ready to go on to make upwelded joints.

When welding material up to 7mm in thicknessplace the pieces 2-3mm apart, run the weldingbead along the join. A second bead can go alongthe underside for extra strength (Fig.9).

When welding material from 7mm to 30mm thickprepare the material as shown in Fig.10 filling upthe space with several layers of weld.

When welding together material over 30mm inthickness prepare the material as shown in Fig.11filling up the space with several layers of weld,welding each side in turn with each welding pass.

Disconnect the Welding Power Supply from themains supply before changing or removingelectrodes. Use pliers to remove used electrodesfrom the electrode holder or to move the weldedpieces.

THE MANUAL METAL ARC PROCESSWhen an arc is struck between the metal rod(electrode) and the workpiece, both the rod andworkpiece surface melt to form a weld pool.Simultaneous melting of the flux coating on the rodwill form gas and slag which protects the weld poolfrom the surrounding atmosphere. The slag willsolidify and cool and must be chipped off the weldbead once the weld run is complete (or before thenext weld pass is deposited). The process allowsonly short lengths of weld to be produced before anew electrode needs to be inserted in the holder.

Fig. 9

Fig. 10

7mm

60º

Fig. 11

2-3mm

>30mm

2-3mm

1243

5 6

60º

>30mm

2-3mm

STICK (MMAW) BASIC WELDING TECHNIQUEWeld penetration is low and the quality of the welddeposit is highly dependent on the skill of thewelder.

TYPES OF FLUX/ELECTRODESArc stability, depth of penetration, metal depositionrate and positional capability are greatly influencedby the chemical composition of the flux coating onthe electrode. Electrodes can be divided into threemain groups:

• Cellulosic

• Rutile

• Basic

Cellulosic electrodes contain a high proportion ofcellulose in the coating and are characterised by adeeply penetrating arc and a rapid burn-off rategiving high welding speeds. Weld deposit can becoarse and with fluid slag, deslagging can bedifficult. These electrodes are easy to use in anyposition and are noted for their use in the stovepipe(vertical down position) welding technique.

Features:• Deep penetration in all positions

• Suitability for vertical down welding

• Reasonably good mechanical properties

• High level of hydrogen generated - risk ofcracking in the heat affected zone

Rutile Electrodes contain a high proportion oftitanium oxide (rutile) in the coating. Titanium oxidepromotes easy arc ignition, smooth arc operationand low spatter. These electrodes are generalpurpose electrodes with good welding properties.They can be used with AC and DC power sourcesand in all positions. The electrodes are especiallysuitable for welding fillet joints in the horizontal/vertical position.

Features:• Moderate weld metal mechanical properties

• Good bead profile produced through theviscous slag

• Positional welding possible with a fluid slag(containing fluoride)

• Easily removable slag

Basic electrodes contain a high proportion ofcalcium carbonate (limestone) and calcium fluoride(fluorspar) in the coating. This makes their slagcoating more fluid than rutile coatings - this is alsofast-freezing which assists welding in the verticaland overhead position. These electrodes are usedfor welding medium and heavy section fabricationswhere higher weld quality, good mechanicalproperties and resistance to cracking (due to highrestraint) are required.

Features:• Low hydrogen weld metal

• Requires high welding currents/speeds

• Poor bead profile (convex and coarse surfaceprofile)

• Slag removal difficult

Iron powder electrodes contain an addition ofmetal powder to the flux coating to increase themaximum permissible welding current level. Thus,for a given electrode size, the metal deposition rateand efficiency (percentage of the metal deposited)are increased compared with an electrodecontaining no iron powder in the coating. The slagis normally easily removed. Iron powder electrodesare mainly used in the flat and horizontal/verticalpositions to take advantage of the higherdeposition rates. Efficiencies as high as 130 to140% can be achieved for rutile and basicelectrodes without marked deterioration of thearcing characteristics but the arc tends to be lessforceful which reduces bead penetration.

CARE OF ELECTRODESThe quality of weld relies upon consistentperformance of the electrode. The flux coatingshould not be chipped, cracked or, moreimportantly, allowed to become damp.

DRYING OF ELECTRODESDrying is usually carried out following themanufacturer's recommendations andrequirements will be determined by the type ofelectrode.

19

STICK (MMAW) WELDING TROUBLESHOOTING

20

Problem Possible Cause Remedy

Welding currentvarying.

A gap is left by failure ofthe weld metal to fill theroot of the weld.

Non-metallic particlesare trapped in the weldmetal.

A groove has beenformed in the basemetal adjacent to thetoe of a weld and hasnot been filled by theweld metal (undercut).

Control knob is set at a value thatcauses the welding current to varyexcessively with the arc length.

Welding current too low.

Electrode too large for joint.

Insufficient gap.

Non-metallic particles may betrapped in undercut from previousrun.

Joint preparation too restricted.

Irregular deposits allow slag to betrapped.

Lack of penetration with slagtrapped beneath weld bead.

Rust or mill scale is preventingfull fusion.

Wrong electrode for position inwhich welding is done.

Welding current is too high.

Welding arc is too long.

Angle of the electrode is incorrect.

Joint preparation does not allowcorrect electrode angle.

Electrode too large for joint.

Insufficient deposit time at edge ofweave.

Reduce the control knob until weldingcurrent is reasonably constant whileprohibiting the electrode from stickingto the workpiece when you “dig” theelectrode into the workpiece.

Increase welding current.

Use smaller diameter electrode.

Allow wider gap.

If a bad undercut is present clean slagbout and cover with a run from asmaller gauge electrode.

Allow for adequate penetration androom for cleaning out the slag.

If very bad, chip or grind outirregularities.

Use smaller electrode with sufficientcurrent to give adequate penetration.Use suitable tools to remove all slagfrom corners.

Clean joint before welding.

Use electrodes designed for position inwhich welding is done, otherwiseproper control of slag is difficult.

Reduce welding current.

Reduce the length of the welding arc.

Electrode should not be inclined lessthan 45° to the vertical face.

Allow more room in joint formanipulation of the electrode.

Use smaller gauge electrode.

Pause for a moment at edge of weaveto allow weld metal buildup.

21

STICK (MMAW) WELDING TROUBLESHOOTING

Problem Possible Cause Remedy

Portions of the weld rundo not fuse to thesurface of the metal oredge of the joint.

Gas pockets or voids inweld metal (porosity).

Crack occurring in weldmetal soon aftersolidificationcommences.

Excessive spatter

Small electrodes used on heavycold plate.

Welding current is too low.

Wrong electrode angle.

Travel speed of electrode is toohigh.

Scale or dirt on joint surface.

High levels of sulphur in steel.

Electrodes are damp.

Welding current is too high.

Surface impurities such as oil,grease, paint, etc.

Welding in a windy environment.

Electrode damaged ie. fluxcoating incomplete.

Rigidity of joint.

Insufficient throat thickness.

Weld current is too high.

Improper welding polarity

Long Arc Length.

Weld current is too high.

Use larger electrodes and preheat theplate.

Increase welding current.

Adjust angle so the welding arc isdirected more into the base metal.

Reduce travel speed of electrode.

Clean surface before welding.

Use an electrode that is designed forhigh sulphur steels.

Dry electrodes before use.

Reduce welding current.

Clean joint before welding.

Shield the weld area from the wind.

Discard damaged electrodes and onlyuse electrodes with a complete fluxcoating.

Redesign to relieve weld joint ofsevere stresses or use crackresistance electrodes.

Travel slightly slower to allow greaterbuild up in throat.

Decrease welding current.

Make sure the electrode holder isplugged into the positive “+” outputterminal.

Move the electrode closer into theweld joint.

Decrease welding current.

22

MAINTENANCEWARNING. ELECTRIC SHOCK can kill.Have an electrician install and servicethis equipment.

Turn the input power off at the fuse box, disconnectsupply lines and allow machine to sit for fiveminutes minimum to allow the power capacitors todischarge before working inside this equipment.

Do not touch electrically hot parts.

WARNING. Do not open this machineand do not introduce anything into itsopenings. Power supply must be

disconnected from the machine before eachmaintenance and service. After each repair,perform proper tests to ensure safety.

CAUTION. The power supply must bedisconnected from the machine beforeeach maintenance and service. Always

use gloves in compliance with the safetystandards.

ROUTINE MAINTENANCEThe welder must be kept clean and dry at all times.Use a dry cloth to clean the welder.

Keep the electrodes clean and dry and ensure allcables are in good condition.

Keep the louvre passages clean to avoid a build upof dirt and oxides inside the machine, which canreduce machine output.

The nozzle will occasionally need to be cleaned ofspatter from welding. Clean it with a metal brush.When the nozzle deteriorates or can no longer becleaned, it will need to be replaced. Unscrew thenozzle and replace it with a new one.

Always try to avoid getting particles of metal insidethe machine since they could cause short circuits.

Periodically clean the inside of the welder withcompressed air, ensuring you wear a mask duringthe operation.

Caution: Water must never come into contact withthe welder.

Regularly check the general condition of the tool.Check for loose screws, misalignment or binding ofmoving parts, cracked or broken parts, damagedelectrical wiring, and any other condition that mayaffect its safe operation.

If the supply cord requires replacing, the task mustbe carried out by the manufacturer, themanufacturer’s agent, or an authorised servicecentre to avoid a safety hazard.

WELDING MASK MAINTENANCEAlways maintain your welding mask in goodcondition. If the clear glass protection lens be-comes badly pitted, sufficient to interfere with vi-sion, or cracked, have it replaced immediately.

NEVER use any dark filter lens other than thatprovided by RYOBI, or one with the same certified‘Optical class’ (degree of protection).

The shield should always be cleaned with a cleansoft cloth after use, ensuring the lenses are clean.Remove any dust that may have accumulated andstore it in a safe place where it cannot bedamaged.

NEVER use a shield that is not in perfect condition.

ELECTRODE STORAGEElectrodes should always be kept in a dry andwell-ventilated store. It is good practice to stackpackets of electrodes on wooden pallets or rackswell clear of the floor. Also, all unused electrodeswhich are to be returned should be stored so theyare not exposed to damp conditions to regainmoisture. Good storage conditions are 10°C aboveexternal air temperature. As the storage conditionsare to prevent moisture from condensing on theelectrodes, the electrode stores should be dryrather that warm. Under these conditions and inoriginal packaging, electrode storage time ispractically unlimited. It should be noted thatelectrodes are now available in hermetically sealedpacks which obviate the need for drying. However,if necessary, any unused electrodes must beredried according to manufacturer's instructions.

23

TROUBLESHOOTING

Problem Possible Cause Remedy

The welding arc cannotbe established.

Maximum outputwelding current cannotbe achieved withnominal mains supplyvoltage.

Welding currentreduces when welding.

Welder will not start.

No weld output withready light on.

No weld output; hightemperature light on.

Fan not operating.

The primary supply voltage has notbeen switched ON.

The welding power sourceswitch is switched OFF.

Loose connections internally.

Defective control circuit.

Bad work clamp to workpiececonnection.

No power at outlet.

Cord not connected.

Line voltage incorrect.

Weld cable loose.

Bad work clamp to workpiece con-nection.

Welder overheated.

Duty cycle or amps too high.

Airflow is blocked.

Fan blocked/dirty.

Fan broken.

Switch ON the primary supply voltage.

Switch ON the welding power source.

Have an qualified service technicianrepair the connection.

Have an qualified service technician in-spect then repair the welder.

Ensure that the work lead has apositive electrical connection to thework piece.

Check power at outlet.

Check that cord is plugged in.

Make sure the welder is plugged into a230V electrical outlet.

Tighten weld cable connection atwelder.

Make sure the area where the clamp isattached is clean, exposed metal; freeof dirt, paint and oil.

Allow unit to cool with the fan on.

Reduce duty cycle or amps.

Clean vents and fan out withcompressed air.

Remove obstruction and clean withcompressed air.

Have the fan replaced by a qualifiedservice technician.

DANGER! Follow all safety precautions whenever diagnosing or servicing the tool. Disconnect power supply before service.

24

TROUBLESHOOTING

SYMBOLSSome of the following symbols may be used on this tool. Please study them and learn their meaning.Proper interpretation of these symbols will allow you to operate the tool better and safer.

SYMBOLS DESIGNATION/EXPLANATION

Conforms to relevant safety standards.

To reduce the risk of injury, the user must read and understand the operator’s manual beforeusing this product.

Warning! Electrical welding process.

Do not use this welder in damp conditions.

Protect operator and passerby from the effect of uV radiation. This can cause permanentdamage to the eye. Make sure the arc and resulting flash is shielding at all times.

Waste electrical products should not be disposed of with household waste. Please recyclewhere facilities exist. Check with your Local Authority or retailer for recycling advice.

Keep bystanders and pets clear of the welding power supply when in use.

Always wear approved face mask with correct filter, gloves and apron to protect againstwelding operation.

Problem Possible Cause RemedyErratic or improper arcor welding output.

Main supply fuse shutsoff frequently.

Bad weld connections.

Polarity incorrect.

Workpiece painted or dirty.

Nozzle obstructed by weldingspatter.

Circuit Breaker rating is too low.

Clean and tighten weld connections.

Connect polarity correctly.

Clean workpiece thoroughly.

Clean or replace nozzle.

Install a circuit breaker rated forgreater than ?? Amps.

25

SYMBOLS

Symbols and Technical Data

European standard relating to Welding Power Supply’s for limited use

MMA-140 Type ID

Single phase transformer

Symbol for manual arc welding and covered electrodes

50Hz Nominal mains frequency

Ø Diameter of electrodes

U0 No load voltage

…A/…V to …A/…V Range of output

X% Duty cycle

I2 Conventional welding current

U2 Conventional load voltage

U1 Mains voltage

I1 max Maximum absorbed current

I1 eff Effective supply current

IP21S Grade of protection

Standardised plug

Suitable for welding in an environment with increased hazard of electric shockS

EN 60974-1

26

NOTES

27

NOTES